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Piaggio Ciao Clutch Replacement

Video Guide
This guide was transcribed from a YouTube video.

Introduction

Use this guide to remove and replace the clutch on a Piaggio Ciao without a variator. The clutch connects the engine to the drive system, and removing it lets you service or replace the clutch shoes, clutch bell, washers, or spacer. This procedure shows how to remove the clutch without a pneumatic impact wrench by locking the crankshaft with a piston stop. Don't wedge a screwdriver into the flywheel to hold it still.

What you need

  1. Edit

    • Set the Piaggio Ciao on a stable stand with the engine off and cool.

    • This procedure applies to Piaggio Ciao models without a variator.

    • Gather a spark plug wrench, a piston stop, a 50 cent coin, and a 17 mm combination wrench.

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  2. Edit

    • Use a coin about the size of a 50 cent coin to unlock the three side-cover pins by turning each pin 90 degrees.

    • Move the pedal arm downward to access the lower pin.

    • Press the lower pin inward and turn it 90 degrees.

    • Remove the side cover from the clutch side of the moped.

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  3. Edit

    • The clutch is fixed to the crankshaft, so the clutch will spin unless the crankshaft is locked.

    • Don't lock the flywheel by wedging a screwdriver into it.

    • Use a piston stop to lock the crankshaft safely and avoid damaging the flywheel or engine.

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  4. Edit

    • Pull the spark plug cap off the spark plug.

    • Use a spark plug wrench to unscrew the spark plug counterclockwise.

    • Thread the piston stop into the spark plug hole by hand.

    • Make sure the piston stop threads in smoothly so you don't cross-thread the cylinder head.

    • The piston stop blocks the crankshaft so the clutch nut can be loosened.

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  5. Edit

    • Use a 17 mm combination wrench to loosen the clutch nut counterclockwise.

    • Finish unscrewing the nut by hand.

    • Remove the safety washer.

    • Keep the nut and washers in order so they return to the same positions during reassembly.

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  6. Edit

    • Remove the washer from the crankshaft.

    • Remove the clutch shoes from the crankshaft.

    • Slide the clutch bell off the crankshaft.

    • Slide the spacer off the crankshaft last.

    • Keep the spacer with the other clutch parts so it isn't lost before reassembly.

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Conclusion

Install the replacement clutch and removed parts in reverse order. Remove the piston stop, reinstall the spark plug, attach the spark plug cap, and lock the side-cover pins before starting the engine. Repair didn't go as planned? Ask our Answers community for help.

Author

Game Man

Member since: 03/02/25

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